Cased goods inspection system and method

ABSTRACT

A method of inspecting cased goods includes advancing at least one case of goods on a conveyor, generating an illumination sheet of parallel illuminating rays with at least one electromagnetic source, and capturing an image, formed by the illumination sheet passing through a diffuser with at least one camera located so as to capture illumination from diffused parallel rays of the light sheet, where the image case embodies a goods image that is generated by the case goods moving between the light source and the at least one camera, where part of the parallel sheet of light is at least partially blocked by the case of goods, thus generating a gray level image.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims the benefit of U.S.Provisional Patent Application No. 62/287,128, filed on Jan. 26, 2016,the disclosure of which is incorporated herein by reference in itsentirety.

TECHNICAL FIELD

This invention relates to product inspection, and particular cased goodsinspection systems and methods therefor.

BACKGROUND

There is a need to improve cased goods inspection systems and methods.

The other cased good inspection systems are mostly built on LED curtainlighting. The LEDs in these arrays have a considerable spacing betweenthem (>5 mm), so they only produce a ‘sampled’ image, instead of imagingthe cased goods completely. The other main disadvantage of LED lightcurtains is the lack of transparency measurement. The light curtainsonly detect the presence of material its path. They are therefore unableto differentiate a piece of shrink wrap from an opaque cardboard piece.

Other approaches use the laser triangulation method. This approach isfast, precise and robust, but is sensitive to reflective surfaces likeshrink wraps. Also, like the previous method, it cannot differentiate apiece of shrink wrap from cardboard.

Therefore, there is a need in the market for a new approach thatintegrates speed, resolution, robustness and cost for inspection casedgoods.

SUMMARY

In accordance with aspect of the proposed solution there is provided acased goods inspection system adapted to determine the presence ofproduct being scanned and to obtain at least “real box”, “max box”, “maxbulge”, “orientation angle”, “distance from one side of the conveyor”,etc. measurements.

In accordance with another aspect of the proposed solution there isprovided a cased goods inspection system adapted to reject or acceptproduct based on allowable dimensions applied at least to “real box”,“max box” and “max bulge” measurements.

In accordance with a further aspect of the proposed solution there isprovided a cased goods inspection system with sensor(s) adapted to senseincident light intensity variations, and detector(s) detecting andaccounting for such incident light intensity variations experienced by avision system of the cased goods inspection system to reduce falseproduct detection and false measurements including rejection adverseeffects to Measurement accuracy from opaque translucent materialspackaging such as plastic shrink wrap.

In accordance with a further aspect of the proposed solution there isprovided a cased goods inspection system adapted to identify thepresence of debris on a window of a camera subsystem of the cased goodsinspection system to reduce false product detection or falsemeasurements.

In accordance with a further aspect of the proposed solution there isprovided a cased goods inspection system adapted to inspect an array ofgoods at least partially encased in shrink wrap packaging.

In accordance with a further aspect of the proposed solution there isprovided a cased goods inspection system adapted to inspect an array ofgoods having complex shapes encased in shrink wrap packaging.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one”, butit is also consistent with the meaning of “one or more”, “at least one”,and “one or more than one”. Similarly, the word “another” may mean “atleast second” or “more”.

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “include” and “includes” or “containing” (andany form of containing, such as “contain” and “contains”), are inclusiveor open-ended and do not exclude additional, recited elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood by way of the following detaileddescription of embodiments of the proposed solution with reference tothe appended drawings, in which:

FIG. 1 is a schematic diagram illustrating perspective view of a caseinspection system in accordance with the proposed solution;

FIG. 2 is a diagram ill illustrating a perspective view of an example ofa product case inspected in accordance with the proposed solution;

FIG. 3 is a schematic chart illustrating a product detection processflow diagram accordance with the proposed solution;

FIG. 4 is a diagram illustrating a general acquired image withoutproduct seen by a camera vision system in accordance with the proposedsolution;

FIG. 5 is a diagram illustrating regions of interest analyzed from thegeneral image illustrated in FIG. 4 in accordance with the proposedsolution;

FIG. 6 is a diagram illustrating one analyzed region from FIG. 5zoomed-in in accordance with the proposed solution;

FIG. 7 is schematic chart illustrating product measurement process flowdiagram in accordance with the proposed solution;

FIG. 8 is a schematic diagram illustrating in side and top views productmeasurement results obtained by e processes of FIGS. 3 and 7 inaccordance with the proposed solution;

FIG. 9 is a schematic diagram illustrating in side and top views realbox product measurements obtained by the processes of FIGS. 3 and 7accordance with the proposed solution;

FIG. 10 is a schematic diagram illustrating in side and top viewsoutside box product measurements obtained by the processes of FIGS. 3and 7 in accordance with the proposed solution;

FIG. 11 is a schematic diagram illustrating in side and top views maxbulge measurements obtained by the processes of FIGS. 3 and 7 inaccordance with the proposed solution; and

FIG. 12 diagram illustrating detection of the presence of debris on acamera system window in accordance with the proposed solution,

wherein similar features bear similar labels throughout the drawings.References to “top” and “bottom” qualifiers in the present specificationis made solely with reference to the orientation of the drawings aspresented in the application and do not imply any absolute spatialorientation.

DETAILED DESCRIPTION

A proposed cased goods inspection system will now be described withreference to illustrative embodiments thereof.

System Input and Output

With reference to FIG. 1, as an input, the proposed case inspectionsystem receives products A which arrive individually on a conveyor B inany orientation and position. For example, conveyor B can be a conveyorbelt. The output of the case inspection system includes various(quantitative) measurements which characterize each product, for examplea case of goods. Examples of quantitative measurements include: “realbox”, “max box”, “max bulge”, “orientation angle”, “distance from oneside of the conveyor”, etc.

One example of a case of good(s) is a shrink wrapped product and/orproduct container or array of one or more product containers orproduct(s) included in shrink wrap as illustrated in FIG. 2. The term“product” should be construed herein as including any type of consumergood (s) in any type of packaging, such as, without limitations, closedcartons, totes, open top cartons, trays with or without shrink wrappedfilm, bags and pouches, etc. The dimensions of “input” product A mayvary greatly between different types of product. Typical dimensions(W×L×H) can be between 4″×4″×2″ and 25″×30″×30″. Though the example inFIG. 2 is illustrated as having a general hexahedron shape, theproduct(s) and/or product case may have any desired 3-D shape ascylindrical, curvilinear, pyramidal, ovoid, etc., and one or moresurface(s) of any side may be curved or pitched with respect to anotherside or another surface on the same side.

System Components

With reference to FIG. 1, the case inspection system can include: inputconveyor B, a vision system generally labeled as C, a controller D, anoutput (human machine interface) screen E (FIGS. 8 to 12) and an outputconveyor J.

At least some of these system components will now be described in moredetail.

Input conveyor B transports incoming products from external equipment.Conveyor B, for example, includes a mat top high-grip conveyor, but canbe of any other form (such as roller bed) allowing moving product A intoand through the vision system C with reduced vibration and slippage. Forexample, acceptable vibration can be under a vibration threshold limit.

The output conveyor J transports product A away from vision system C.Conveyor J, for example, includes a mat top low-grip conveyor, but canbe of any other form allowing moving product A through and away from thevision system C with reduced vibration. For example, acceptablevibration can be under a vibration threshold limit.

Vision system C is positioned, at least in part, around and about theconveyors B and/or J for measuring the top and side profiles of productA.

In accordance with one aspect, the vision system C can includes a firstlight source F which emits a (first) sheet of light (not shown), e.g. acontinuous plane of substantially parallel light, within a small gapbetween conveyors B and J. For example first light source F can belocated above conveyors B and J as otherwise shown in FIG. 1.

The vision system further includes a first camera system G located forexample opposite first light source F with respect to conveyors B and J,positioned to receive the parallel light emitted by first light sourceF. For example if first light source F is located above conveyors B andJ, then the first camera system G is located below conveyors B and J. Inother aspects, the orientation of first light source and first camerasystem may be rotated as desired about the axis defined by the directionof travel of conveyors B and J maintaining the relationship betweenlight source emitter and camera system receiver.

A second light source H emits a (second) sheet of light, i.e. acontinuous plane of substantially parallel light, over the small gapbetween conveyors B and J. For example second light source H can belocated on one side of conveyors B and J (transmission of the parallellight beams of the second sheet being substantially (orthogonal to thefirst plane).

A second camera system I is correspondingly located to receiveillumination from (e.g. opposite) second light source H with respect toconveyors B and J, positioned to receive the parallel light emitted bysecond light source H. For example if second light source H is locatedto one side of conveyors B and J, then second camera system I is locatedto the other opposite side of conveyors B and J.

A controller or any other device or system (local or remote) operablycoupled to the system, includes a computer program that is capable ofregistering and analyzing image data to calculate desired measurementsof products A.

Without limiting the invention, at least one light source F or H caninclude a light shaper LS made with lenses or mirrors. The light sourceitself can be a laser, a LED or other types like gas lamp. In otheraspects the source may be any other device of EM radiation suitable forEM illumination of a target object and which reflection or transmission,of which may be captured by an appropriate imaging system generating animage or pseudo image of the illuminated target object.

The collimated output beam provides the sheet of parallel propagatinglight which, when impeded by the product A, casts an orthographicprojection shadow onto an input window of the corresponding camerasystem G or I opposite the corresponding light source F or H. In thisregard, the camera system G or I receives an incident collimated inputbeam output by the corresponding light source.

In the illustrated example, both camera systems G and I include a cameraCAM, an optional mirror MIR and a diffusion screen DIF. The optionalmirror MIR is for example employed in reducing the footprint of theoverall cased goods inspection system by redirecting the sheet of lightparallel to the conveyor. The diffusion screen DIF, which may be anysuitable type illumination diffuser, is an example of an input beamshaper spreading the input beam by diffusing the parallel light incidentthereon from corresponding light sources F or H so that thecorresponding camera G and I (e.g. the camera imaging array having adesired predetermined width, defined structurally or by the controllerso that the array) can capture and digitize diffused light from the fullwidth of the corresponding light sheet emitted by the light source. Asmay be realized, the camera(s) G, I may image a case(s) and/or productswithin the full width of the light sheets (which as may be furtherrealized may span the lateral bounds of the conveyor and height of theinspection system opening).

In order to reduce the light footprint or to be able to use a lesspowerful laser class light source, smaller sheets of parallel light canbe used, with overlap to maintain continuity and cover the largersurface. A calibration procedure can be used to realign these separatesheets as a single one by software.

Operation

For example, in operation, a product A arrives on conveyor B in anyorientation and position. Without limiting the invention, the positionincludes a distance or gap from one side of conveyor B. FIG. 3illustrates a product measurement process.

Vision system C makes repeated image acquisitions, block 310, into imagecache storage (such as of the controller processor), for exampletriggered by an input conveyor encoder or alternatively by a steppermotor drive circuit advancing at least one of the conveyors B and J.FIG. 4 illustrates a representative example of what may be referred toas a raw acquired image obtained (with the imager of the camera) at agiven encoder index value, such as may be generated for a four lightsources (e.g. as may be used in either light source(s) F, H) and onecamera system (e.g. camera system(s) G, I) implementation. The imageincludes subregions of illuminated and unilluminated (unexposed) pixels4GI, 4GV. The image analysis computer program algorithm does notconsider the complete acquisition region of the camera image sensorwhere the pixels are not exposed. Instead, a specific subregion 4GI, forexample having a height 4H of 3 pixels and of the complete light sheetwidth 4W, is considered. FIG. 5 illustrates regions considered 5GI (suchas may correspond to such light source), identified with dotedrectangles representing registered image subregions 5L, processed theimage analyzer. FIG. 6 shows a detail of one specific region 6GIenlarged to better illustrate the region being considered by the imageanalysis algorithm.

For each acquired image (FIG. 4), the image analysis algorithm comparesblock 320, pixel light intensity of pixels in the specific region 5 h(FIG. 5) being analyzed with a normalized intensity value obtained froma comparable subregion sample, for example from 10 raw baseline sampleimages. With reference to FIG. 3, the normalizing baseline may be arolling baseline wherein at each image acquisition step 320 (in whichthere no potential detection as will be described), the oldest image inthe sample is deleted from registry or erased and replaced by a newlyacquire draw image 322. The number of images used in the baseline samplecan be modified. The normalized intensity value can be representative ofan ambient lighting level, for example accounting for lighting conditionchanges in the surrounding environment of the cased goods inspectionsystem, and the presence of dust, liquid residues or small debris on theoptical receptor.

Using, for description purposes, the image acquired from the camerasystem G located below the conveyors B and J, the controller verifies330 whether the number of pixels in a considered portion of an acquiredimage (registered by at least one or if desired, acquired imagesregistered by both camera's G, I) which have a drop in intensity of morethan, for example, about 40% compared to the normalized intensity value,and that represent a width of, for example, about 30 mm or more from thefull width of the illumination sheet captured by the acquired image. Asmay be realized, the width referred to herein as the threshold width ofreduced intensity portions of the acquired image may be set as desiredbased on environmental conditions. The reduced intensity width of theimage portion corresponds to and is the result of a spatial intensityreduction caused by sustained, over the duration of acquired image(s),disruption and/or obstruction or block of at least a portion of theinput beam(s) forming the illumination sheet, such as due to an object,that may be opaque or translucent in part passing through thebeam/sheet. In other words, passage of product, case and/or wrappingthrough the sheet produces what may also be referred to as a gray levelimage for at least part of the acquired image width. If this is thecase, the controller considers that there is a potential detection 332of a product. The threshold value (both threshold width and thresholdintensity variance) of the drop in intensity may be modified as desired(for example intensity drop threshold may be 10% drop from normalized).As may be realized, both thresholds settings are determinative ofportion of opaque or translucent material in the illumination sheet, thedisruption thereof resulting in a gray image which such material is bothdetectable and measurable as will be further described (and thethreshold width may be about 5 mm). By comparison, a wholly opaquematerial will reflect resulting in substantially complete obstruction ofillumination and consequently in the relevant portion of the, or thegraphic projection image.

The above process stems 310-340 are repeated as long as the number ofpixels in a given acquired image, which have a drop in intensity of morethan the predetermined threshold intensity drop (that may also berepresented as an absolute intensity value threshold), for example,about 40%, and represents a width greater than the predeterminedthreshold width of, for example, about 30 mm or more and the processstops when this condition is not true anymore. While this firstcondition is true (established by exceeding both thresholds), if thenumber of images that meet this condition represents a potential productlength of about 60 mm (as may be determined by a suitable encodersynchronizing acquisition rate, identifying conveyor displacement andrate so as to be correlated or proportional to acquired images and/orimage frames) or more, the controller considers that a product wasdetected, or in other words, confirming detection as true 336 (thepotential product length for confirmation of product may be set more orless, such as 10 mm of displacement. In this case, the controllercombines previously acquired upstream images representing, for example,60 mm of conveyor displacement (the representative length may be more orless, e.g. 10 mm) in front of the image setting the detection of thedetected product, the number of images in which product was detected,and subsequently acquired downstream images representing, for example,60 mm of conveyor displacement after the product detection assertion,from both camera systems I and G, to construct 340, a compositecontiguous complete combined image of the product from the series ofimages acquired during the aforementioned durations before and afterproduct detection (the duration(s) pre and/or post detection) may bevaried and need not be symmetrical. If the number of images that meetthe first and second conditions (i.e. threshold and duration 330, 336)represent a potential product less than, for example, 60 mm inwidth/length, the controller asserts that the detection 337 was a falsedetection, or that the detected product is below the minimal acceptedlength/width the image acquisition process continues normally. Thissystem robust to noise or parasitic signals like falling debris.

As noted, a while both conditions are asserted, contiguous constructionof the combined image (or pseudo image) of the scanned product continuespast, for example, 60 mm until a maximum accepted product dimension isreached. In other words, upon controller determination that acquiredimage(s) (corresponding to desired conveyor travel, 60 mm) for example,of camera system G (through such determination maybe effected fromacquired images if both cameras G, I) no longer satisfies the abovenoted thresholds (e.g. the considered portion of the acquired imageshave neither the width nor an intensity drop, greater than the setthresholds (e.g. 30 mm, 40% drop)), the controller registers theaccepted product dimension (such as from the registered conveyordisplacement from the encoder coincident with image acquisitions thatexceed thresholds). Accordingly, the controller (via suitableprogramming) effects raw image acquisition for combination into thescanned product combined image may continue for another, for example, 60mm after the maximum accepted product dimension was surpassed. It isunderstood, that the “combined image” (or pseudo image) and the“combined product image” correspond to the relative positions andorientations of illumination sources and include images of substantiallyorthogonal sides of the product such as a side and a top view images.

Once, and if desired substantially coincident with processor constructof the composite image(s) of a complete image product as noted, thecontroller calculates a variety of quantitative measurements by processsteps illustrated in FIG. 7. With reference to FIG. 8, examples ofquantitative measurements include: “real box” “max box”, “max bulge”,“orientation angle” and “distance from one side of the conveyor”.

“Real box” measurements, block 710 include dimensions of the best fitshape which can be determined based on, or obtained from, the combinedproduct image. For example, the shape employed in the fit is a boxhaving a length, width and height. Alternatively, the shape employed canbe a sphere having a center and a radius. Various other shapes can beemployed in the fit, such as but not limited to a cylinder, ovaloid,cone, etc. FIG. 9 illustrates and example of “real box” measurements(shown with the dotted lines on the processed images 9A, 9B respectivelyrepresenting elevations and plan combined images) obtained fromcomposite images acquired/combined/constructed during the inspection ofthe product shown on FIG. 2. As it can be seen in this example, anyprotrusion seen by the vision system C is not regarded as such when the“real box” dimensions are determined. In the example, the label L on thecased goods illustrated representative product as illustrated in FIG. 2is partially detached and is detected in the confined image and resolvedas part of the best fit shape determination so as to be ignored in thefootprint evaluation. Nonetheless, opaque or translucent materials wrapsfor example, embodied in the composite material, are included in realbox measurements to the extent conformal to the best fit shape.

“Outside box” measurements, block 712 include dimensions of the smallestshape that contains the entire product which can be determined based on,or obtained from, the combined product image (as may include protrusionsseen by the vision system including distressed product portion, labelsand wrapping). For example, the shape employed in the fit is a boxhaving a length, width and height indicative of the largest rectangularfootprint of the product A on the conveyor B/J. Alternatively, the shapeemployed can be a sphere having a center and a radius. Various othershapes can be employed in the fit, such as but not limited to acylinder, ovaloid, cone, etc. FIG. 10 illustrates and example of“outside box” measurements obtained from the images (10A, 10Brespectively representing (evaluation and plan combined images)acquired/combined/constructed during the inspection of the product shownon FIG. 2 (shown with the dotted lines on the processed image). As itcan be seen in this example, any protrusion imaged by the vision systemC including such gray image projecting parts indicative of translucentor opaque wrapping, is considered an included when the “outside box”dimensions are determined. In the example, the partially detached labelL on the cased goods product A illustrated in FIG. 2 dominates indetermining the footprint of product A.

The “max bulge” measurement block 714 is the longest dimension obtainedfrom the product A being inspected. FIG. 11 illustrates a “max bulge”measurement obtained from the images 11A, 11B (with similar conventionsto FIGS. 9, 10) acquired/combined/constructed during the inspection ofthe product shown on FIG. 2. Once the orientation of the product isdetermined, the “max bulge” is the biggest caliper measure in width, inlength and in height.

The product “orientation angle” is the angle of the product's main axisrelative to the travel direction of product A on the conveyors B/J. FIG.8 best illustrates a non-zero product “orientation angle” determinedwhen a box is employed for the best fits. Without limiting theinvention, the “orientation angle” measurement can be a major axis whenan ovaloid shape is employed in the fits.

With reference to FIG. 8, a “distance from one side of the conveyor” isdetermined as the minimum distance obtained between the product andeither of the predetermined conveyor sides (as expressed based on thewidth of the light sheet, see FIG. 6).

For certainty, the proposed solution is not limited to performing thesteps illustrated in FIGS. 3 and 7 in the sequence illustrated.Determination of measurements, as well as condition testing, arepreferably performed in parallel, for example ascertained as theconveyors B/J advance. The sequence of steps illustrated in FIGS. 3 and7 can illustrate a hierarchy of a coded logic decision network.

Once a substantial number of the above mentioned measurements aredetermined, the image analysis computer program compares them in block718 with nominal values and accepted tolerances provided in block 716 tothe cased goods inspection system. For example, a Programmable LogicController (PLC) (not shown) can provide at least some of the nominalvalues and accepted tolerances for the given case inspected by theinspection system. According to preferences of the user, the “real box”,the “outside box” or the “max bulge” can be considered to accept orreject product A.

The vision system C then sends its decision (accept or reject), 720A,720B as well as the various measurements taken to another controller forsubsequent use by the user 722. For example, at least conveyors B/J canbe operated in a special way to retract or dump rejected product,alternatively paddles (not shown) can be actuated to deflect rejectedproduct possibly onto another conveyor (not shown). In anotherimplementation, large “orientation angles” can be reduced by actuatingcomponents of the cased goods inspection system For certainty, adecision to reverse conveyors B/J and rescan the product is not excludedfrom the scope of the proposed solution.

In accordance with a preferred embodiment, as it can be seen from theraw image example illustrated in FIG. 4, the recorded light intensitydoes vary within the acquired image. To establish a normalized baselinevalue of intensity as a comparison basis or reference, the intensityvalue of non-black pixels of a selectable number, for example, 10 sampleimages are considered. In one aspect, the intensity values of the 33%median images, for example from the selected number of sample images,are considered to establish the normalized value of pixel intensity. Bydoing so, signal noise, light interference, and the like, are eliminatedin order to reduce false product detection or false measurements. Thesample images providing the basis for determination of the normalizedbaseline value of intensity may be updated, or refreshed, on a rollingbasis as previous noted resolving for ambient changes due toenvironmental variances, detritus on noted EM source and/or visionsystem components, etc.)

By using above mentioned process, the vision system C can automaticallycompensate for debris or the like being present on a window panel of thecamera system I/G. When such situation arises, the rawconstructed/combined image shows a narrow line of constant pixelintensity 12D as shown within stitched line 12A, in FIG. 12. Upondetection of a narrow line of pixels, a warning can be sent to theoperator to alert of a need to clean the window. In the meantime,because of the normalization of the light intensity process describedabove, such debris can be gradually relocated or removed by theprocessor from the combined composite image of the product A constructedby the image processing algorithm within a few iterations (encodersteps, stepper motor steps, seconds, etc.) and therefore minimizing theimpact on the operation of the cased goods inspection system.

In accordance with another preferred embodiment of the proposedsolution, the cased goods inspection system is employed to inspect anarray of goods at least partially encased in shrink wrap following thecontour of goods in the array. For simple shaped goods, the acceptable“outside box” and “real box” dimensions are similar within tolerances.Allowance is provided for goods having a complex shapes (such as mayinclude one or more nonlinearities in the shape) as may be formed by oneor more simple shaped product placed in an ordered array withinpackaging (e.g. shrink wrapping)). For example, with reference toproduct illustrated in FIG. 2, acceptable “outside box” dimensions canbe specified to consider bottle tops and caps (as may be determined fromthe side image) beyond bottle necks, while acceptable “real box”dimensions can be specified to consider bottle bodies only, thusresolving imaging effects from the wrapping that may be translucent oropaque. In this case the acceptable “outside box” and “real box”dimensions are generally dissimilar.

The capacity to detect semi-transparency is proves useful to ignoretranslucent or semi-transparent wrap bulge from the measurements. It isto be noted that many other modifications can be made to the cased goodsinspection system described hereinabove and illustrated in the appendeddrawings. For example: it is to be understood that embodiments of thecased goods inspection system are not limited in their application tothe details of construction and parts illustrated in the accompanyingdrawings and described hereinabove. Other embodiments can be foreseenand practiced in various ways. It is also to be understood that thephraseology or terminology used herein is for the purpose of descriptionand not limitation.

While some reference is made herein to a “vision system”, the inventionis not limited to any single nor to any combination of camera systemsoperating in the millimeter wave, Infra Red, visual, microwave, X-ray,gamma ray, etc. spectra. While composite camera can be employed,separate spectrum specific camera can also be employed severally or incombination. Any reference cased goods comprising food stuffs isincidental and not intended to limit the scope of the invention. Forcertainty, durable goods cased in metal shipping containers can beinspected via appropriate sizing of the cased goods inspection systemand appropriate selection of vision systems operating in metal shellpenetrating spectra (X-ray), including electromagnetic sources operatingin corresponding spectra absorbable by the cased goods.

In accordance with one or more aspects of the disclosed embodiment, ascanner apparatus for cased goods inspection is provided. The scannerapparatus including at least one conveyor for advancing a case of goodspast the scanner apparatus, at least one electromagnetic (EM) sourceconfigured to transmit a sheet of parallel propagating EM radiationillumination of predetermined width towards a vision system disposed toreceive the EM radiation illumination from the at least one EM source,the vision system including a diffuser and at least one camera whereinthe diffuser diffuses the EM radiation illumination received from to atleast one EM source so that the at least one camera captures thepredetermined EM radiation illumination sheet width in entirety, the atleast one camera is configured to digitize images of at least a portionof the EM radiation illumination sheet so that the case of goodsadvanced by the at least one conveyor through the transmitted EMradiation illumination sheet cast a shadow thereon, and a processoroperably coupled to the at least one conveyor and vision system andincluding an image acquisition component configured to acquire thedigitized images as the case of goods is advanced past the at least onecamera, and an image combiner configured to selectively combine acquireddigitized images into a combined image based on sustained input beamspatial intensity reduction below a first threshold, wherein theprocessor is configured to determine from the combined image dimensionalmeasurements about the case of goods including one or more of length,width, height, angle, “real box, “max box” and “max bulge”.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is configured so as to ascertain presence of the case of goodsbased on sustained input beam spatial intensity reduction below a secondthreshold discriminating presence of shrink wrap translucency disposedon product in the case of goods.

In accordance with one or more aspects of the disclosed embodiment, theat least one conveyor is configured to advance the case of goods at arate of advance, the image acquisition component being configured toacquire the digitized images at an acquisition rate proportional to therate of advance of the case of goods.

In accordance with one or more aspects of the disclosed embodiment, theimage acquisition rate is synchronized by using an encoder or by astepper motor drive circuit.

In accordance with one or more aspects of the disclosed embodiment, theat least one EM source includes a substantially point source lamp havingan output light beam, an output beam shaper configured to redirect theoutput light beam into the sheet of collimated illumination havingparallel light rays of the output light beam, and an optional mirror toreduce a foot print of the apparatus.

In accordance with one or more aspects of the disclosed embodiment, theimage acquisition component includes an image cache storage.

In accordance with one or more aspects of the disclosed embodiment, thevision system is configured to determine an ambient light intensity froma sample buffer of cached images.

In accordance with one or more aspects of the disclosed embodiment, thevision system is configured to identify presence of debris on an inputwindow of the vision system based on common pixels of same intensityacross a number of digitized images.

In accordance with one or more aspects of the disclosed embodiment, theimage combiner is configured to selectively combine acquired digitizedimages into a potential product combined image if a number of pixelsdigitized in an image having a reduced intensity below the firstpredetermined threshold define an image width greater than a secondthreshold.

In accordance with one or more aspects of the disclosed embodiment, theimage combiner is configured to selectively combine acquired digitizedimages into forming the combined image if a number of pixels digitizedacross sequential images having reduced intensity below the firstpredetermined threshold and a second threshold represent a predeterminedcombined image length.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is figured to determine dimensions from the combined image of:a first shape best fitting in the combined image, a second shapecircumscribing the combined image, and differences between the first andsecond shapes.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is configured to determine from the combined image anorientation angle of the case of goods with respect to the at least oneconveyor.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is configured to determine from the combined image a distanceof the case of goods from one side of the at least one conveyor.

In accordance with one or more aspects of the disclosed embodiment, amethod of inspecting cased goods is provided. The method includesadvancing at least one case of goods on a conveyor, generating anillumination sheet of parallel illuminating rays with at least oneelectromagnetic source, capturing an image, formed by the illuminationsheet passing through a diffuser, with at least one camera located so asto capture illumination from diffused parallel rays of the illuminationsheet, where the image embodies a cased goods image that it generated bythe case of goods moving between the at least one electromagnetic sourceand the at least one camera, where part of the parallel sheet ofillumination is at least partially blocked by the case of goods, thusgenerating a gray level image.

In accordance with one or more aspects of the disclosed embodiment,capturing comprises capturing a number of serial images, each new imageis compared with a normalized intensity from a predetermined number ofpreviously acquired images, and a cased goods is detected, with aprocessor, when there is a drop of intensity more than a predeterminedthreshold.

In accordance with one or more aspects of the disclosed embodiment, acombined image of the cased goods is constructed with the processor byaiding a series of images.

In accordance with one or more aspects of the disclosed embodiment,various characteristics of the cased goods are computed based thecombined image of the cased goods including one or more of the length,the width, the height, the angle, the “real box”, the “max box” and the“max bulge”

In accordance with one or more aspects of the disclosed embodiment, ascanner apparatus for cased goods inspection is provided. The scannerapparatus includes at least one conveyor for advancing a case of goodspast the scanner apparatus, at least one electromagnetic (EM) sourceconfigured to transmit a sheet of parallel propagating EM radiationillumination of predetermined width towards a vision system disposed toreceive the EM radiation illumination from the at least one EM source,the vision system including a diffuser and at least one camera whereinthe diffuser diffuses the EM radiation illumination received from the atleast one EM source so that the at least one camera captures thepredetermined EM radiation illumination sheet width in entirety, the atleast one camera is configured to digitize images of at least a portionof the EM radiation illumination sheet so that the case of goodsadvanced by the at least one conveyor through the transmitted EMradiation illumination sheet cast a shadow thereon, and a processoroperably coupled to the at least one conveyor and visions system andincluding an image acquisition component configured to acquire thedigitized images as the case of goods advanced past the camera, and animage combiner configured to selectively combine acquired images into acombined image based on sustained input beam spatial intensity reductionbelow a first threshold, wherein the processor is configured so as toascertain presence of the case of goods based on sustained input beamspatial intensity reduction below threshold discriminating presence ofshrink wrap translucency desired on product in the case of goods.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is configured to determine from the combined image dimensionalmeasurements about the case of goods including one or more of length,width, height, angle, “real box, “max box” and “max bulge”.

In accordance with one or mere aspects of the disclosed embodiment, theat least one conveyor is configured to advance the case of goods at arate of advance, the image acquisition component being configured toacquire the digitized images at an acquisition rate proportional to therate of advance of the case of goods, and wherein the image acquisitionrate is synchronized by using an encoder or by a stepper motor drivecircuit.

In accordance with one or more aspects of the disclosed embodiment, theat least one EM source includes a substantially point source lamp havingan output light beam, an output beam shaper configured to redirect theoutput light beam into the sheet of collimated illumination havingparallel light rays of the output light beam, and an optional mirror toreduce a foot print of the apparatus.

In accordance with one or more aspects of the disclosed embodiment, thevision system is configured to identify presence of debris on an inputwindow of the vision system based on common pixels of same intensityacross a number of digitized images.

In accordance with one or more aspects of the disclosed embodiment, theimage combiner configured to selectively combine acquired digitizedimages into a potential product combined image if a number of pixelsdigitized in an image having a reduced intensity below the firstpredetermined threshold define an image width greater than a secondthreshold.

In accordance with one or more aspects of the disclosed embodiment, theprocessor is configured to determine dimensions from the combined imageof: a first shape best fitting the combined image, a second shapecircumscribing the combined image, and differences between the first andsecond shapes.

While the invention has been shown and described with reference topreferred embodiments thereof, it will be recognized by those skilled inthe art that various changes in form and detail may be made thereinwithout departing from the spirit and scope of the invention as definedby the appended claims.

What is claimed is:
 1. A scanner apparatus for cased goods inspectioncomprising: at least one conveyor for advancing a case of goods past thescanner apparatus; at least one electromagnetic (EM) source configuredto transmit a sheet of parallel propagating EM radiation illumination ofpredetermined width towards a vision system disposed to receive the EMradiation illumination from the at least one EM source; the visionsystem including a diffuser and at least one camera wherein: thediffuser diffuses the EM radiation illumination received from the atleast one EM source so that the at least one camera captures thepredetermined EM radiation illumination sheet width in entirety, and theat least one camera is configured to digitize images of at least aportion of the EM radiation illumination sheet so that the case of goodsadvanced by the at least one conveyor through the transmitted EMradiation illumination sheet cast a shadow thereon; and a processoroperably coupled to the at least one conveyor and vision system andincluding an image acquisition component configured to acquire more thanone of the digitized images for each of the case of goods as the case ofgoods is advanced past the at least one camera, and an image combinerconfigured to selectively combine a number of acquired digitized images,different than the more than one of the digitized images, into acombined image based on sustained input beam spatial intensity reductionbelow a first threshold over a duration of the more than one of theacquired digitized images; wherein the processor is configured todetermine from the combined image dimensional measurements about thecase of goods including one or more of length, width, height, angle,“real box, “max box” and “max bulge”.
 2. The apparatus as claimed inclaim 1, where the processor is configured to ascertain presence of thecase of goods based on sustained input beam spatial intensity reductionbelow a second threshold discriminating presence of translucent shrinkwrap disposed on product in the case of goods.
 3. The apparatus asclaimed in claim 1, wherein the at least one conveyor is configured toadvance the case of goods at a rate of advance, the image acquisitioncomponent being configured to acquire the digitized images at anacquisition rate proportional to the rate of advance of the case ofgoods.
 4. The apparatus as claimed in claim 3, wherein the imageacquisition rate is synchronized by using an encoder or by a steppermotor drive circuit.
 5. The apparatus as claimed in claim 1, wherein theat least one EM source comprises: a substantially point source lamphaving an output light beam; an output beam shaper configured toredirect the output light beam into the sheet of collimated illuminationhaving parallel light rays of the output light beam; and a mirror toreduce a foot print of the apparatus.
 6. The apparatus as claimed inclaim 1, wherein the image acquisition component comprises an imagecache storage.
 7. The apparatus as claimed in claim 1, wherein thevision system is configured to determine an ambient light intensity froma sample buffer of cached images.
 8. The apparatus as claimed in claim1, wherein the vision system is configured to identify presence ofdebris on an input window of the vision system based on common pixels ofsame intensity across a number of digitized images.
 9. The apparatus asclaimed in claim 1, wherein the image combiner is configured toselectively combine acquired digitized images into a potential productcombined image where a number of pixels digitized in an image having areduced intensity below the first predetermined threshold define animage width greater than a second threshold.
 10. The apparatus asclaimed in claim 1, wherein the image combiner is configured toselectively combine acquired digitized images into forming the combinedimage where a number of pixels digitized across sequential images havingreduced intensity below the first predetermined threshold and a secondthreshold represent a predetermined combined image length.
 11. Theapparatus as claimed in claim 1, wherein the processor is configured todetermine dimensions from the combined image of: a first shape bestfitting in the combined image, a second shape circumscribing thecombined image, and differences between the first and second shapes. 12.The apparatus as claimed in claim 1, Wherein the processor is configuredto determine from the combined image an orientation angle of the case ofgoods with respect to the at least one conveyor.
 13. The apparatus asclaimed in claim 1, wherein the processor is configured to determinefrom the combined image a distance of the case of goods from one side ofthe at least one conveyor.
 14. A method of inspecting cased goodscomprising: advancing at least one case of goods on a conveyor;generating an illumination sheet of parallel illuminating rays, having apredetermined width, less than a width of each of the case of goods,with at least one electromagnetic source; capturing an image, formed bythe illumination sheet passing through a diffuser, with at least onecamera located to capture illumination from diffused parallel rays ofthe illumination sheet; where the image embodies a cased goods imagethat is generated by the case of goods moving between the at least oneelectromagnetic source and the at least one camera, where part of theparallel rays of the illumination sheet is at least partially blocked bythe case of goods, and the image generated spans the predetermined widthof the illumination sheet and encompasses a gray scale image of part ofthe illumination sheet blocked by and transmitted through at least aportion of the case of goods, and where capturing comprises capturing anumber of serial images, each new image is compared with a normalizedintensity from a predetermined number of previously acquired images, anda cased goods is detected, with a processor, when there is a drop ofintensity more than a predetermined threshold.
 15. The method as claimedin claim 14, where a combined image of the cased goods is constructedwith the processor by adding a series of images.
 16. The method asclaimed in claim 15, where various characteristics of the cased goodsare computed based on the combined image of the cased goods includingone or more of length, width, height, angle, “real box”, “max box” and“max bulge”.
 17. A scanner apparatus for cased goods inspectioncomprising: at least one conveyor for advancing a case of goods past thescanner apparatus; at least one electromagnetic (EM) source configuredto transmit a sheet of parallel propagating EM radiation illumination ofpredetermined width towards a vision system disposed to receive the EMradiation illumination from the at least one EM source; the visionsystem including a diffuser and at least one camera wherein: thediffuser diffuses the EM radiation illumination received from the atleast one EM source so that the at least one camera captures thepredetermined EM radiation illumination sheet width in entirety; the atleast one camera is configured to digitize images of at least a portionof the EM radiation illumination sheet so that the case of goodsadvanced by the at least one conveyor through the transmitted EMradiation illumination sheet cast a shadow thereon; and a processoroperably coupled to the at least one conveyor and visions system andincluding an image acquisition component configured to acquire more thanone of the digitized images for each of the case of goods as the case ofgoods is advanced past the camera, and an image combiner configured toselectively combine a number of acquired digitized images, differentthan the more than one of the digitized images, into a combined imagebased on sustained input beam spatial intensity reduction below a firstthreshold over a duration of the more than one of the acquired digitizedimages; wherein the processor is configured to ascertain presence of thecase of goods based on sustained input beam spatial intensity reductionbelow a second threshold discriminating presence of translucent shrinkwrap on product in the case of goods.
 18. The apparatus as claimed inclaim 17, wherein the processor is configured to determine from thecombined image dimensional measurements about the case of goodsincluding one or more of length, width, height, angle, “real box, “maxbox” and “max bulge”.
 19. The apparatus as claimed in claim 17, whereinthe at least one conveyor is configured to advance the case of goods ata rate of advance, the image acquisition component being configured toacquire the digitized images at an acquisition rate proportional to therate of advance of the case of goods, and wherein the image acquisitionrate is synchronized by using an encoder or by a stepper motor drivecircuit.
 20. The apparatus as claimed in claim 17, wherein the at leastone EM source comprises: a substantially point source lamp having anoutput light beam; an output beam shaper configured to redirect theoutput light beam into the sheet of collimated illumination havingparallel light rays of the output light beam; and a mirror to reduce afoot print of the apparatus.
 21. The apparatus as claimed in claim 17,wherein the vision system is configured to identify presence of debrison an input window of the vision system based on common pixels of sameintensity across a number of digitized images.
 22. The apparatus asclaimed in claim 21, wherein the image combiner is configured toselectively combine acquired digitized images into a potential productcombined image if a number of pixels digitized in an image having areduced intensity below the first predetermined threshold define animage width greater than a second threshold.
 23. The apparatus asclaimed in claim 17, wherein the processor is configured to determinedimensions from the combined image of a first shape best fitting in thecombined image, a second shape circumscribing the combined image, anddifferences between the first and second shapes.
 24. The method of claim14, wherein the gray scale image resolves imaging effects of a casing ofthe case of goods relative to the case of goods.